Step 2:
INSTALLATION OF NEW PARTS
Step 1:
PIVOT BALL FRONT SUSPENSION CONVERSION KIT
INSTRUCTIONS
REMOVAL OF STOCK PARTS
Step 1:
A.
B.
C.
D.
E.
F.
Take off the front bumper (key #31) by removing its 2.6 x 10mm mounting screw (N).
Take off the front hinge pin support (key #30) by removing the two 2.6x10mm screws (N) that connect it to the chassis.
Remove the lower hinge pins (key #33) from the front suspension arms.
Remove the caster adjustment clips (key #32) from the upper hinge pins (key #34) to the upper arm mount.
Loosen the two 2 x 6mm screws (G) that keep the upper hinge pins (key #34) in place.
Remove the upper hinge pins (key #34) by sliding them forward.
Step 3:
A. Place a pivot ball (key #1B) into the upper and lower mounting holes in the new knuckles (key #2B and #3B).
B. Using a 2.5mm hex wrench, install the pivot ball retainers (key #4B) curved side in to secure the pivot balls
(key #1B) Tighten the retainers enough to keep the pivot balls from moving in the knuckles, but loose enough to still
rotate smoothly.
C. Install the 3.8mm ball studs (key #40) into the new knuckles (key #2B and #3B)
D. Install two 6 x 10mm bearings (B) into each of the new knuckles (key #2B and #3B).
Step 2:
A.
B.
C.
D.
Remove the 2 x 12mm screws (F) that attach the bottom end of the front and rear shocks to their suspension arms.
Remove the front and rear shocks from their upper shock mounts (key #89).
Remove the 2 x 6mm screws (G) that secure the upper shock mounts (key #89), to the front and rear shock towers.
Take off the front wheels (key #63) and wheel hexes (key #61) by removing the 2.6 x 10mm wheel retaining
screws (N).
A. Remove the steering tie-rods (key #20) from the 3.8mm ball studs (key #40) from the top of the stock left and
right knuckles.
B. Remove the universal assemblies from the center of the 6 x 10mm bearings (B).
C. Remove the four 6 x 10mm bearings (B) and 3.8mm ball studs (key #40) from the original knuckles (key #10 and key #11).
2
A. Use a 2mm hex wrench through the pivot ball retainers to thread the pivot balls into the upper and lower suspension arms
(key #5B, #6B, #7B and #8B). Note: The final camber adjustments should be made once the kit is fully assembled. At this
point the threaded section of the pivot balls should cover half of the round holes in the upper and lower arms.
B. Re-install the universal assemblies in the 6 x 10mm bearings (B).
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Step 4:
Step 3:
REPLACEMENT PARTS LIST
Key #
1B
2B
3B
4B
5B
6B
7B
8B
9B
10B
11B
A. With their L & R markings facing up, secure the new lower suspension arms (key #7B and #8B) to the chassis using the
lower hinge pins (key #33).
B. Re-install the front hinge pin support (key #30) onto the lower hinge pins (key #33). Secure it with two 2.6 x 10mm screws (N).
C. Re-attach the front bumper (key #31) to the front hinge pin support (key #30) using a 2.6 x 10mm screw (N).
D. Place the inner ends of the universals into their differential output joints (key #57).
E. With the L & R markings facing up, secure the new upper arms (key #5B and #6B) by pushing the upper hinge pins (key
#34) through the front shock tower, and into the upper arm mount (key #16).
F. Tighten the 2 x 6mm screws (G) in the upper arm mount (key #16) to secure the upper hinge pins (key #33).
G. Re-install the caster adjustment clips (key #32) to the upper hinge pins (key #34).
H. Re-attach the steering tie-rods (key #20) to the 3.8mm ball studs (key #40) now located on the new knuckles (key #2B
and #3B).
Part #
DTXC6264
DTXC8214
DTXC8214
DTXC8319
DTXC9346
DTXC9346
DTXC9597
DTXC9597
DTXC9183
DTXQ0281
DTXQ8239
A. Replace the wheel hexes (key #64) on the ends of the universal assemblies.
B. Re-install the front wheels (key #63) on the wheel hexes (key #64). Secure them with the 2.6 x 10mm wheel retaining
screws (N).
C. Install the new front and rear upper shock mounts (key #9B) and secure them with the new 2 x 16mm cap screws
(key #10B).
D. Re-install the front and rear shocks on the lower suspension arms using 2 x 12mm screws (F).
E. Place the top of the shocks onto the new upper shock mounts (key #9B) and secure them with the 2mm lock nuts
(key #11B).
Entire Contents © Copyright 2008
4
Description
Pivot Balls
Left Knuckle
Right Knuckle
Aluminum Pivot Ball Retainers
Upper Right Suspension Arm
Upper Left Suspension Arm
Lower Right Suspension Arm
Lower Left Suspension Arm
Upper Shock Mounts
2 x 10mm Cap Screws
2mm Lock Nut
5
DTXC8312INST01